ERNST PENNEKAMP Operating Instructions

Cold End Coating Unit CES650/2-S7

INDEX

1 GENERALITIES .......................................................................................................................................... 5
1.1 Spraying Unit Layout ............................................................................................................................. 6
Phase diagram ................................................................................................................................................. 6
1.2 good/bad rows ........................................................................................................................................ 7

2 Operating Modes ........................................................................................................................................... 8

3 OPERATOR PANEL KTP600 ................................................................................................................... 9

3.1 Key Functions ....................................................................................................................................... 9
3.1.1 HELP-KEY .................................................................................................................................... 9
3.1.2 ESC- KEY ....................................................................................................................................... 9
3.1.3 ENTER- KEY ................................................................................................................................. 9
3.1.4 DEL- KEY .................................................................................................................................... 9
ACK-LED ....................................................................................................................................................... 9
HELP-LED...................................................................................................................................................... 9
SCHIFT-LED .................................................................................................................................................. 9
3.1.5 CURSOR-KEY „left ..................................................................................................................... 10
3.1.6 CURSOR-KEY „right“ ................................................................................................................. 10
3.1.7 ACK-KEY ..................................................................................................................................... 10
3.1.8 CURSOR-KEY „UP“ ............................................................................................................... 10
3.1.9 CURSOR-KEY “DOWN“ ............................................................................................................ 10
3.1.10 SHIFT-KEY ................................................................................................................................. 10
3.1.11 INPUT-KEY ............................................................................................................................... 10

4 SIGNAL LAMPS ....................................................................................................................................... 11

4.1 Signal Lamp Operation (green signal lamp) .................................................................................. 11
- Blinking light cycle 1 second ...................................................................................................................... 11
- Continuous light.......................................................................................................................................... 11
Quick blinking............................................................................................................................................... 11

6 OPERATING ELEMENTS.................................................................................................................. 12
6.1 Function Keys of the Operator Panels OP77 ........................................................................ 12
6.2 operating elements at the second Operation Position ................................................................. 13
6.3 Button Emergency-Off ...................................................................................................................... 13

7 .1 Operating of Menu Functions of the KTP600 ....................................................................... 14

7.1.1 Example for the Menu functions of the KTP600 (example for the input of the length of drive
way) 15
set value CONTINUOUS .............................................................................................................................. 15
PAUSE TIME: 00 ms ......................................................................................................................... 15

7.2 Adjusting of Operating Mode ........................................................................................................... 16

Pos1: Pos2: ................................................................................................................. 16
Pos1: Pos2: ................................................................................................................. 16

7.3 menu EVENT......................................................................................................................................... 17

7.4 menu ALARMS ..................................................................................................................................... 18

7.5 Menu Calculation .................................................................................................................................. 19

7.5.1 input menu CALCULATION ............................................................................................................ 20

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7.5.2 result menu CALCULATION ..................................................................................................... 20

speed: XX % ................................................................................................................................... 20

7.6 menu set value ..................................................................................................................................... 21

7.6.1 Set Values for light barrier operation and continuous operation ............................................ 21
SPEED: % ............................................................................................................................................. 21
set value LIGHT............................................................................................................................................ 21
set value LIGHT............................................................................................................................................ 21
Input .............................................................................................................................................................. 21
minimum GAP: 00 ms ........................................................................................................................... 21
set value LIGHT............................................................................................................................................ 21
superviosion LIGHT ..................................................................................................................................... 21

All set values can be modified immediately at the Operator Panel KTP600 also during the
spraying cyle ..................................................................................................................................................... 21

of the spray rail. ................................................................................................................................................ 21

The following set values mentioned below are only effective when the spray rail has reached its
initial position (Position 1). ............................................................................................................................ 21
7.6.2 set value for light barrier operation ............................................................................................. 23
set value LIGHT............................................................................................................................................ 23
set value LIGHT............................................................................................................................................ 23
Input .............................................................................................................................................................. 23
set value LIGHT............................................................................................................................................ 23
7.6.3 set value for continuous operation .............................................................................................. 24
superviosion LIGHT BARR.......................................................................................................................... 24

7.7 menu real value..................................................................................................................................... 25

7.8 menu RECIPE ....................................................................................................................................... 27

7.9 menu SPEZIAL ..................................................................................................................................... 29

17.9.1 Menu DATE / TIME ....................................................................................................................... 29
7.9.2 menu LANGUAGES ......................................................................................................................... 29

7.10 menu PASSWORD .......................................................................................................................... 31

7.11 menu OPTION .................................................................................................................................... 32

7.12 service menu DATA ........................................................................................................................ 32

Gap1: XXX Gap3: XXX .............................................................................................................................. 33

7.13 menu HELP help for the adjustment of the spray rail ............................................................. 34
7.13.1 menu structure of menu HELP .................................................................................................... 35
menu HELP ................................................................................................................................................... 35
menu HELP ................................................................................................................................................... 35
input toerance ............................................................................................................................................... 35
STARTSIGNAL : 00 ms....................................................................................................................... 35
menu HELP ................................................................................................................................................... 35
input .............................................................................................................................................................. 35
minimum GAP: 00 ms ......................................................................................................................... 35

7.14 START UP ........................................................................................................................................... 36

8 PHASE INDICATION OF SIGNAL LAMPS ......................................................................................... 37

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ERNST PENNEKAMP Operating Instructions
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9 FAULT ALARM INDICATION at the Operator Panel KTP600 ........................................................ 38

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ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

1 GENERALITIES
The spray rail serves to spray glass articles at the cold end of the
annealing lehr.

The spraying of the glass items improves their gliding quality and
reduces the defects which may be caused by friction.

The spraying unit displaces one or various spray guns, which are
moving above or between the glass article rows.

The speed of this movement is infinitely variable via an asynchronous motor which is
controlled by a frequency converter.

So as to prevent any coating product from entering the articles‘ mouth, spraying is
executed in-between the glass rows which is possible due to the inclined position of
the drive unit and the light barrier regulation.

In case the light barrier cannot detect proper row distances, as for example some
bottles have been aligned incorrectly, this row will be
sprayed with gun lifted up or no spraying is executed, depending on the
respective adjustment. The start signal then is given by an internal impulse transmitter
which is corresponding to the time cycle of the article rows.

The operation and fault indication of the spray rail is made at the KTP600.

The spray rail is switched on via the main switch 5S1, the green signal lamp
OPERATION is flashing in cycles of about 1 second, thereby signalising that the spray
rail is ready for operation.

In case there is no switching off disturbance, the spray rail can be switched on for
operation by pushing the key K1 at the Operator Panel KTP600 (first operating
position)
or the button START (second operating position) from STOP STATE to OPERATION
STATE.

At the operator panel KTP600 of the spray rail two operating modes can be adjusted:

Continuous operation
Light Barrier Operation

At the Operator Panel KTP600 it is possible to adjust in the operating mode light
barrier whether a spraying of the article rows is allowed with spray gun lowered down
only. Thereby it is avoided that any spray product will be sprayed into the articles‘
mouth.

Signal Lamp (RED)

Disturbance
Control Panel Spraying Unit

Signal Lamp (GREEN)

Operation

Control Panel Fan Operator Panel OP07

Main Switch –5S1

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 ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

1.1 Spraying Unit Layout EMERG: OFF

2.Operating Pos.

Position 1 Position 2

1.Operating Pos.

Position 1 without Position 2 without

spraying spraying

Displacement Way
rweg
Phase diagram
Magnetic valve

Real spray process at

movement from pos.
1 to pos. 2 Due to the mechanical inertia the
spray medium leaves the spray gun
delayed.

Delay Delay

Ideal spray process

at movement from
pos. 1 to pos. 2

Ideal spray process

at movement from
pos. 2 to pos. 1

With the input „Spraying

earlier ON“ at the Operator
Panel KTP600 the spray gun
can be switched on earlier.

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ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

1.2 good/bad rows

Signaldiagramm light barrier Light phase of the light

Distance of the article Dark phase of the light

rows

The light barrier supervises the light duration between two

article rows (gap) as well as the temporal distance of the
gap article rows (time cycle of the article rows).
Distance of the article rows: This is the temporal
difference from one signal change of the light barrier
(passing over from light to dark) to the next signal
change (passing over from light to dark)
gap: This is the measured light duration of the lioght
Light Barrier barrier betwen two article rows. The light barrier is
necessary to measure whether a spraying course
has to be carried out between or over the article
rows. The operator can enter a minimum gap at
the Operator Panel KTP600 of the spraying unit.
Due to this entry difference is made between bad
and good article rows in the light barrier
operation.

Spray gun

Good Article Rows:: There are no articles between the

article rows and the light duration of the light barrier
betwen two article rows is bigger than the LIGHT
DURATION min. gap adjusted at the Operator Panel
KTP600.
At next signal of the light barrier (from light to dark) the
spray rail carries out a spraying cycle with the spray gun
down between the rows.

Bad Article Rows: There is an article between the

article rows. For this reason the gap between two article
rows which is measured by the light barrier (light
duration of the light barrier) is smaller than the LIGHT
DURATION min gap adjusted at the Operator Panel
KTP600
As per the respective adjustment at the Operator Panel
KTP600(good rows only or every row)the spray rail
carries out then either no spraying cycle or sprays with
spray gun lifted up. The start impulse is given then by
the generator of the PLC.

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ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

2 Operating Modes

STOP

The spray rail is switched on by the main switch and can be switched into the operation state
1
(continuous operation or light barrier operation by the button „K1“ at the operator Panel KTP600 or
by the button „START“ at the second operation position.

Operating mode change

at the operator panel
KTP600 in the menu
Operation.
Continuous

The the operating mode CONTINUOUS the spray rail is working

without start signal of the light barrier. The spray movement is
started automatically after the waiting time (pause) adjusted at
the Operator Panel KTP600. In the operating mode
CONTINUOUS a spraying of the article rows is possible only
with spray gun lifted up.

Light Barrier Mode

In the operating mode LIGHT BARRIER the spray rail is started via a light barrier signal. Moreover the light
barrier supervises the temporal distance rows as well as the gap (light duration of the light barrier) between
the article rows.
When the spray rail is witched on the average temporal article row distance and the temporal average value
of the gap is calculated out of four good article rows (this is shown by a quick flashing in 100 ms cycle of the
green signal lamp). After this measuring has been completed, the average value of the article row distance is
memorised as internal generator of the PLC. This internal generator is actualised continuously with the
actual signal of the light barrier.

Difference is made between bad and good rows in the light barrier operation

With the adjustment at the Operator Panel KTP600 you can chose whether every row or only good rows
shall be sprayed.

Enter Change at the

Operator Panel KTP600 in
Spray only good rows the menu set values. Spray every row
Good rows are sprayed with gun Godd rows are sprayed with gun
down, bad rows are not sprayed. down, bad rows with gun lifted up.

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ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

3 OPERATOR PANEL KTP600

3.1 Key Functions

3.1.1 KEY "F1“:

Switching ON / OFF the Spray Rail

3.1.2 SPRAYING –KEY (F2)

Die Betätigung der ESC-Taste bewirkt das Einschalten der Sprühpistole. Jetzt kann in Posi.1 oder
Posi 2. Der Sprühstrahl und die Intensität eingestellt werden.

3.1.3 LAMPENTEST- KEY (F3)

Durch drücken und halten der Taste Lampentest leuchten alle Signallampen der Spritzbrücke auf.
Somit kann eine defekte Leuchte ermittelt werden.

3.1.4 MAIN – KEY (F5)

Durch Betätigung der MAIN-Taste gelangen Sie ins Hauptbild der Visualisierung der Spritzbrücke.

3.1.5 ACK- KEY

Not acknowledged Fault messages are blinking with the system’s blinking frequency.
Acknowledging of each fault message at the KTP600 is done when the operator pushes
the ACK-KEY.

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ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

4 SIGNAL LAMPS

4.1 Signal Lamp Operation (green signal lamp)

- Blinking light cycle 1 second

The spray rail is switched on and is in STOP condition.

- Continuous light
The spray rail is in OPERATION condition and can start at any time after a start
impulse.

Quick blinking
The operation mode light barrier is selected and the average temporary distance of
the article row is calculated by the PLC. the spray rail starts after
start impulse has arrived.

Attention: When the signal lamp OPERATION is on,

the spray rail can start at any time.

4.2 Signal Lamp FAULT (red signal lamp)

This signal lamp signalises faults at the unit or within the electric regulation.

- New disturbances are signalised by a FLASH LIGHT

- acknowledged but still existing faults are signalised by a CONTINUOUS LIGHT .

TROUBLE SHOOTING

Acknowledge at the Operator Panel KTP600

The fault messages are indicated at the Operator Panel KTP600.

When a fault message arrives, this is designated with + as “arriving message” and shown
at the display as blinking message as long as it is acknowledged by the operator at the
Operator panel KTP600 with the acknowledge key “ACK”. Still existing disturbance
messages are indicated at the Operator Panel KTP600 with the illuminating LED of the
acknowledge key. When the disturbance message is no more existing (fault message
acknowledged by the operator) this is designated as gone with “-“.

Attention !
Fault messages are reset only then if they are acknowledged with the button “ACK”

In case of failure of the KTP600 the disturbance can be acknowledged by the adjusting
switch SPRAYING/button START by short pushing to the right.

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ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

6 OPERATING ELEMENTS
6.1 Function Keys of the Operator Panels OP77

KEY "F1“: Switching ON / OFF the Spray Rail

Switching ON: When the spray rail was switched on by the main switch and
when there is no fault with switching off effect, the spray rail can
be switched on by pressing the key „F1“. (Condition: the spray
rail was switched off). The lighting up of „F1”-LED and signal lamp
OPERATION signalise that the spray gun is switched on.

Switching OFF: After pushing the key „F1“ the spray rail is switched off when it
has reached the initial position (Initiator 0-point). (Condition: the
spray rail was switched on). The „F1“-LED and the green signal
lamp OPERATION pass over into blinking (cycle frequency 1s). The
spray rail is in STOP condition.

KEY"F2": ACTIVATE / DEACTIVATE test Spraying

ACTIVATE: When the spray rail is stopped, „TEST GUN SPRAYING“ can be
activated via the key “F2“and the LED lights up. So the
adjustment of the spray gun can be done.

DEACTIVATE: When the key „F2“ is again pushed or the spray rail is switched
on, the test is deactivated.

KEY "F3": Lamp test

This key indicates a Lamp test. The signal lamp and LED’s of the
KTP600 lights up, when the key „F3“ is pressed.

KEY"F5": MAIN Sprung ins Spritzbrücken Hauptmenü

KEY "ACK“: Acknowledgement of Faults

Occurring faults are indicated by flash light of the red signal lamp and
shown in the clear text at the OP77.

By pushing the key „ACK“ the red lamp passes over into steady light,
in case the fault is still present. The red signal lamp only extinguishes,
when the fault has been removed. At the KTP600 the number of faults
which have arrived and which are still existing are indicated in the
submenu fault messages.

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ERNST PENNEKAMP Operating Instructions
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6.2 operating elements at the second Operation Position

This chapter describes the operating elements at the second Operating Position.

Switch SPRAY / button START

The adjusting switch SPRAY (button START) has two functions:

a) Switching On the spraying rail

In case there is no trouble with switching-off effect, the spray rail can be switched on
by turning the adjusting switch SPRAY / button START to the left.

The spray rail is moving then slowly unto the position „initial position“, with the guns
lifted up. The lighting up of the green signal lamps OPERATION shows that the spray
rail is switched on and will carry out a spray cycle after having reached the position
„initial position“ at next start signal.

b) Test "Spray Gun“

By turning the adjusting switch SPRAY / button START to right the spray rail the spray
nd
rail moves into position 2 „2 operating position“ during the cycle. The movement is
stopped whereby the spray guns remain switched ON in order to enable an exact
spraying adjustment.

The signal lamp OPERATION blinks every one second.

6.3 Button Emergency-Off

When this button is pressed the spray rail is immediately switched off. By turning and
pulling out this switch can be released again.

ATTENTION:
When working at the spray rail this button always
should be pushed!

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ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

7 Operating of Menu Functions of the KTP600

The KTP600 is an operating panel allowing to visualise processes. Due to the limited
dimension of the LC-display a picture hierarchy was established for the operating of the
spray rail to allow the operator to change within the various pictures.

Message Level

The message level is the highest level at the OP. In the message level existing operating
and disturbance messages as well as system messages are shown. After starting, the OP
changes into the message level, when a system or disturbance message exists.

The disturbance and operating messages are released by the PLC and transferred to the
KTP600. If a message is existing, the KTP600 recognises the respective message as come,
and after the message has been reset it is recognised as gone.

Operating messages indicate at status in the process.

e.g.. - Spray rail switched on
- operating mode CONTINUOUS
operating mode LIGHT BARRIER

-Fault Messages indicate faults and have to be acknowledged at the KTP600 due to their
importance.
e.g. Button Emergency-off 9S2.1/9S2.2
Prox. switch 0-position faulty – 12B4
Check Main contactor -9K4

-System messages are released by the KTP600 and inform about operation states of the KTP600
and about fault operation (see more details in the manual Operator Panel KTP600).

Picture level:
In the picture level functions (e.g. input length of the spray way) are selected and operated.

The operator can see actual process values, enter and modify values (which have to be
acknowledged then with the ENTER key. Changing between the various levels can be done
via the Symbolkeys.

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 ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

7.1 Example for the Menu functions of the KTP600

(example for the input of the length of drive way)

Bildanwahl: Störungsanalyse

Bildanwahl: Einstellung Querfahrt

Bildanwahl: Einstellungen

Bildanwahl: Betriebsartanwahl Quittierung anstehender

Störungen und RESET

Bildanwahl Parameter für

Lichtschrankenbetrieb. Wird erst
auswählbar wenn Lichtschranken
betrieb aktiv ist.

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ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

7.2 Adjusting of Operating Mode

Display and adjustment of the operating modes

Operation mode (Continues / Light barrier)
Input Speed (V) of the spray The change of the operation mode may only be
movement in % executed when CES is stopped.

Indication Spraying
GUN ↑ = = Spraying only with gun UP
(Continuous
Operation)
GUN ↓ = = Spraying only with gun down
(Light Barrier only good rows are
sprayed))
GUN ↑↓ = Spraying with gun UP and DOWN-
(Light operation spraying each row)

Input depending on the operation

mode CONTINUOUS OPERATION
Waiting time (pause) in 1/10 seconds
in Position 1 and Position 2.

LIGHT OPERATION: minimum light

duration in 1/10 seconds of the light
barrier between two article rows.

Input position 2 without

spraying in cm.

Input position 1 without Displacement Way Input spraying sooner on

spraying in cm in cm.

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ERNST PENNEKAMP Operating Instructions
Cold End Coating Unit CES650/2-S7

7.3 menu ALARMS

Line 1: group message numbers

sign + for disturbance come or
sign – for disturbance gone or
no sign for acknowledged alarm only at the KTP6007.

The alarm are divided up into two groups:

- Group 01: fault messages of switching-off effect
- Group 02: fault messages of no switching-off effect

Line 2: Date and time of fault messages which have come,.

gone or which have been acknowledged at the KTP600.

The contents of the alarm memory can be shown via the arrow keys “Up/Down”

The message text of the marked event can be shown via the arrow keys “right”.

In the submenu “Number” all alarms which are in the event memory are divided up in
- total alarms
still existing alarms

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7.5 Menu Calculation

A correct inclined position for the lateral displacement is necessary, to compensate the
movement of the annealing lehr belt during a spraying cycle.

A correct input of the main speed (V) in % for the spray movement is necessary to make
sure that the spray guns remain in the middle between two rows during the whole cycle.

The main speed as well as the adjustment of the lateral displacement can be calculated by
the PLC in the menu CALCULATION by means of

input number of articles in a minute

input number of articles in a row
input distance of article rows in mm

Calculation by PLC.

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ERNST PENNEKAMP Operating Instructions
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7.5.1 input menu CALCULATION

(password level1)

01:
spray each ROW
Input number of rows which should be sprayed at one travel
Input = 1 one time spraying with one gun in each row
Input = 2 two time spraying with two guns in each row (so that each row is
sprayed in the double spray time

The input of the DRIVE WAY is done in the menu “Input of Set values” by entering the
length of the drive way in cm.

02:

ARTICLE / MINUTE: Input the number of articles per minute coming from the
IS-machine)
(Maschinenleistung pro Minute)
ARTICLE / ROW: Input the number of articles per row in spraying direction
(Artikelanzahl / Reihe)

Input distance article rows in mm. See chapter 1.2 (good/bad rows).

By pushing the function key „F2“ (CALC) the calculation is activated. After the calculation
is ready. screen changes into the menu “result calculation”. The “menu calculation is
finished with the function key “F4” (ESC).

7.5.2 result menu CALCULATION

Result of the calculation are shown:

01: The output value for the speed is not taken over automatically by
the PLC. The value must be entered manually in the menu „Adjust
set values“.
The output value inclined position indicates the adjust value in mm
for the lateral displacement.
Scroll into the next screen with button F4.

02: The output value for the inclined position is directly converted into
adjust values for the graduation at the hand wheel (black and red
pointer)

7.6 menu set value

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ERNST PENNEKAMP Operating Instructions
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(password level 1)

The following set values are valid for light barrier

and continuous operation.
- Input length of spray way
- Input speed
- Input Position 1 without spraying
- Input Position 2 without spraying
- Input Spraying sooner ON

7.6.1 Set Values for light barrier operation and continuous operation
S02: Input length of the DRIVE WAY in cm.
-upper limit = Depending on the constructional dimensions of the spray rail, the
maximum input is limited.

- Lowest Input = 100cm

S01: Input speed of spray movement

Largest Input = 99%
Lowest Input = 10%

S03: Input of position 1 without spraying in cm

When advancing to the second operation position (spray movement from pos. 1 to
pos. 2) the switching-on of the spray gun in pos. 1 is delayed by the amount,
which was adjusted at the operator panel KTP600.

When returning to the initial position (spray movement from pos. 2 to pos. 1) the
switching off of the spray gun in pos. 1 takes place earlier in relation to the
amount, which was adjusted at the operator panel KTP600.

Example:
Input = 100 cm
Exactly 100 cm driveway starting from position 1, without spraying
Largest Input = 200 cm
Lowest Input = 0 cm

S04: Input of position 2 without spraying in cm

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ERNST PENNEKAMP Operating Instructions
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Beim Fahren vor zur 2.Bedienstelle (Sprühbewegung von Position 1 nach Position 2)
schaltet die Sprühpistole um den im Operator Panel KTP600 eingegebenen Wert, in der
Position 2, eher aus.

When advancing to the second operation position (spray movement from pos. 1 to
pos. 2) the switching-on of the spray gun in pos. 2 is delayed by the amount,
which was adjusted at the operator panel KTP600.

When returning to the initial position (spray movement from pos. 2 to pos. 1) the
switching- off of the spray gun in pos. 2 takes place more early in relation to the
amount, which was adjusted at the operator panel KTP600.

Example:
Input = 100 cm
Exactly 100 cm driveway starting from position 2, without spraying
Largest Input = 200 cm
Lowest Input = 0 cm

S05: Input SPRAYING at start more early ON in cm.

With the input “SPRAYING at start earlier ON” it is possible to switch-on the spray
rail more early. This helps to build to the spray pressure in the spray gun more
early.
When driving from pos. 1 to pos. 2 the spray gun is switched-on more early in
relation to the adjusted value.
When driving from pos. 2 to pos. 1 the spray gun is switched-on more early in
relation to the adjusted value.

The inputs for pos. 1 and pos. 2 are the same.

Largest Input = 50 cm
Lowest Input = 0 cm

Attention: When modifying the drive speed of the spray rail, the input values of
SPRAYING have to be adapted eventually.

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The following set values are valid for the light

barrier operation only

- Input minimum light duration of the light barrier

- Input Difference start signal of the light barrier
- Input Supervision light barrier
- Input Spraying with gun lifted up ON/OFF
(ON = each row is sprayed)
(OFF = only good rows are sprayed )

7.6.2 set value for light barrier operation

S07: Input :each Spraying with gun lifted-up is allowed
Each row will be sprayed.
Good rows will be sprayed by the gun in down position.
Bad rows will be sprayed by the gun in up position.

Input: No spraying with gun lifted-up.

only good Good rows will be sprayed in down position.
Bad rows will not be sprayed

Procedure: 1. Press Key SHIFT

2. choose good row or every row with the Cursor Key
3. acknowledge with ENTER

S09: Input of the minimum light duration (gap) of the light

1
barrier between two rows in /10 of a second.
Largest Input = 99
Lowest Input = 5
S10: Input DIFFERENCE of the start signal of the light barrier in 1/10 seconds.
During the learning phase of the spray rail the input “Difference Start
Signal” determines the maximum admissible difference between two
measured start signals. If the input value is too low there is the risk that
the internal time cycle, which has been found by the PLC, cannot be
calculated.
As help check real value difference in the menu real values.
Largest Input = 20
Lowest Input = 5

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set value for continuous operation

1
Input of the PAUSE TIME at position 1 and 2 in /10 of a second.
Alle Sollwerte können auch während des Sprühverlaufs der Spritzbrücke, am Operator
Panel KTP600 sofort verändert werden.
Die folgenden unten aufgeführten Sollwerte sind aber erst dann wirksam, wenn die
Spritzbrücke ihre Ausgangsstellung (Position1) erreicht hat.

Länge Fahrweg
Geschwindigkeit
Position 1 ohne Sprühen
Position 2 ohne Sprühen
Sprühen bei Anlauf eher ein

7.6.3 set value for continuous operation

1
Input of the PAUSE TIME at start position 1 and end position 2 in /10 of a second.
After finishing the break the spraying unit got a starting impulse and starts spraying.

Largest Input = 99
Lowest Input = 5

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7.7 menu real value

01: actual gap: Display shows the real value of the actual gap between
1
two rows in /10 of a second. (light duration of light barrier).
difference gap:
Time difference between the actual gap and the
1
gap before in /10 of a second.
02: actual start sig:
Display shows the time between two start signals
in 1/10 of second.(Signal change of light barrier from light to dark).
difference start sig:
Difference start signal is the temporal difference between the
values of start signal which were measured actually and before.
This output value serves as orientation help for the
Input Difference Start Signal.
03: time cycle rows:
Time cycle article rows is the temporal article distance which has
been calculated by the PLC after the measuring out of four good rows.
This values corresponds to the internal generator

bad rows: Number of bad rows, at which the measured gap is smaller
than the minimum gap (Input Operator Panel KTP600)
(Eingabe HELLDAUER min. Lücke).

7.8 menu RECIPE

The set values for another production can be memorised as recipe in the Operator Panel
and be called in again if necessary. The user will give a name to each data file (production)
to enable better finding back. New data files can be re-filed and also copied.

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7.9 Menu SPEZIAL

7.9.1 Menu DATE / TIME

In the menu DATE / TIME the date and the time will be put in by using the key “F1”.
By pressing key “F2” the correct input will be transmitted to the PLC.

Adjust date and time by pressing „F1“

Change Date
Position the cursor on the input for the day. Press “SHIFT” for starting the input. By
using the cursor keys “UP” and “DOWN” you could choose the correct day. Afterwards
please press the cursor key “RIGHT” to go to the input for the date. Put in the date by
using the figure keys. Acknowledge your input by pressing the “ENTER” key.

Change Time
Position the cursor by using the cursor key ”RIGHT” at the input for the time. By using
the figure keys the time could be put in. Acknowledge your input by pressing the
“ENTER” key.

To go back to menu DATE / TIME you must push the “ESC” key.
To transmit the edit date and time to the PLC, please press “F2”. The date and time is
now stored and transmitted.

7.9.2 Untermenü Einstellungen

Im Untermenü Einstellungen lassen sich die Benutzerverwaltungen, Sprachen Datum/Uhrzeit einstellen und die
Runtime stoppen.

Achtung !
Es wird für die Einstellung der Helligkeit und der Gerätesprache Paßwortebene 9 (höchste Ebene)
eingegeben

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7.10 menu OPTION

Submenu option

It is shown at the display of the Operator Panels KTP600 whether an option is released or
blocked. .

01: option second light barrier

Input ON Second light barrier is activated
Input OFF Second light barrier is deactivated

02: option tact of second cold end spraying unit

Input after how many rows the second spraying bridge should start, in case the first
main spraying bridge is not spraying.
Largest amount = 15
Lowest amount = 5

03: Option 1 light barrier with various spray guns

Largest input: 4
Lowest input: 1

04: Option activate/deactivate supervision maximum flow

05: Versetz. Lichtschr. Um XX Reihen

06: Früherkennung der Reihen durch LS

8 START UP

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The spray rail is switched on via the main switch (signal lamp OPERATION s flashing)

Disturbance signals shown at the KTP600 are acknowledged with the ACK button.

Enter the displacement way of the spray rail in cm in the menu Enter Set Value.

Calculate the adjustment for the inclined position and adjust it at the hand wheel.

The main speed as well as the adjustment for the inclined position can be calculated
in the menu CALCULATION of the PLC. The value for the speed is not taken over
automatically by the PLC (see menu Calculation).

Choose the desired operating mode (continuous operation or light barrier) at the
KTP600 and enter the speed.

Adjust the light barriers and reflectors or the guns parallel to the article rows in a way
that the guns are in the middle between the rows when starting.

At various light barriers and reflectors install them in a way that the distance between
the two light barriers or the reflectors are corresponding to the distance of the article
rows on the annealing lehr belt.

For alignment of the light barrier locate the reflector over the upper edge of the
housing. When the red light spot is in the middle of the reflector, the alignment is
optimal.

Estimate the time for the minimum gap (light duration of the light barrier) between two
article rows and enter it at the Operator Panel KTP600 (in menu Operation or in the
menu Enter Set Values.

Start the spray rail over the key K1 at the KTP600, the „K1“-LED lights up and the
signal lamp OPERATION flashes (cycle approx. 100ms), the temporal average value
of the gap and the temporal article distance out of four good rows is calculated, When
the calculation is ready, the signal lamp OPERATION lights up in continuous light and
the minimum gap calculated by the PLC is indicated at the Operator Panel KTP600 in
the menu Operation.

This value can be modified by the operating personnel.

Adjust the light barriers and reflectors or the guns parallel to the article rows in a way
that the guns are in the middle between the article rows when starting.

Displace the carriage on the opposite side in a way that the guns are in the middle
between the rows when moving back.

Eventually the main speed has top be adapted in a way that the guns remain in the
middle between the rows during the whole cycle.

The operator has the possibility, to select a help menu for the adjustment
of the spray rail (see menu HELP) at the operator panel KTP600.

9. PHASE INDICATION OF SIGNAL LAMPS

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OPERATING MODE SL-operat. SL-faults

Stop FLASHING OFF

cycle 1 second
Continuous CONTIN. OFF

Light barrier FLASHING OFF

during learning phase cycle 100m second
Light barrier CONTIN. OFF
after the learning phase
via key "K1"
Change from operation to FLASHING OFF
STOP cycle 1 second
Position 1 not yet reached
via key "K1"
Change from operation to FLASHING OFF
STOP cycle 1 second
Position 1 reached
via adjusting switch spray
Change from operation to FLASHING OFF
STOP cycle 1 second

DISTURBANCE FLASHING BLINKT

with switching-off effect cycle 1 second cycle 1 second

DISTURBANCE CONTIN. BLINKT

no switching-off effect cycle 1 second

DISTURBANCE XXX CONTIN.

acknowledged but still existing

"K1“-LED Signal lamp "K1"(on / off) at the Operator

Panel KTP600
SL-Operation green Signal Lamp

SL-Disturbance red signal lamp

XXX no defined signal state

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10 FAULT ALARM INDICATION at the Operator Panel KTP600

These described faults could be removed by the operator:

- Button EMERGENCY OFF is actuated

- Flow supervision: Flow too low
- Running time higher than 50 seconds
- Adjusting switch SPRAY/button START on the second operation position is in
position RIGHT , that means test „Spraying Gun“ when the OP-key K1 is actuated.
- Light barrier not adjusted

Steps to remove the fault

a) Unlock button EMERGENCY-OFF

b) Check flow quantity
c) Check Motor 10M3 for mechanical overcharge
d) Switch over adjusting switch SPRAY/ button START
e) Light barrier - 12A6 or –25A2 have misadjusted or the supervision time of the
light barrier in the menu
„Set Value Light Barrier. Input Time for Supervision "LS" has been adjusted on
a too small value.

The following fault messages must be removed by an skilled electrician:

- Fault 24 V DC PLC - Inputs

Reason: No voltage at the PLC input E124.7.

Removal: Switch on automatic over current fuses -5F8. Check connections.

- Fault Contactor Drive Motor

Reason: No voltage at PLC input E125.3

Removal: Check connections, Contactor–9K4

- Fault Drive Motor overload switch

Reason: There is voltage at the PLC input E124.5

Removal: Switch on again overload switch –10Q3

- Fault Frequency Converter

Reason: There is voltage at the PLC input E124.6

Removal: Frequency –10A3 converter is not ready

- Fault 24 V DC PLC outputs

Reason: No voltage at PLC input E 125.0

Removal: Check connections, switch on again automatic over current fuses 5F7

- Fault Initiator has not reached 0-position.

Reason: Initiator -12B4

Removal: Check connections to PLC input E126.1

- Fault Final position not reached

Reason: Movement is not finished

Removal: check motor for mechanical charge

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- Fault Excessive temperature control panel

Reason: no cooling
Removal: Check air-condition –7M6

- Fault Failure of battery buffer

Reason: Battery defect

Removal: install new battery

- Disturbance external release is missing

Reason: No voltage at the PLC input E124.0

Removal: Check connection of the strip terminal X3:5 and X3:6

- Disturbance proximity switch for counting impulses defective

Reason: no impulses from prox. switch –14B4

Removal: Check prox. switch –14B4

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